IBP1090_19

THE ROLE OF INTERNAL INSPECTION IN THE

INTEGRITY MANAGEMENT OF FLEXIBLE
RISERS, FLOWLINES AND PIPELINES
Andrew Burton, Roland Palmer-Jones, Manuel Quack

Copyright 2019, Brazilian Petroleum, Gas and Biofuels Institute - IBP

This Technical Paper was prepared for presentation at the Rio Pipeline Conference and Exhibition 2019, held
between 03 and 05 of September, in Rio de Janeiro. This Technical Paper was selected for presentation by the
Technical Committee of the event according to the information contained in the final paper submitted by the
author(s). The organizers are not supposed to translate or correct the submitted papers. The material as it is
presented, does not necessarily represent Brazilian Petroleum, Gas and Biofuels Institute’ opinion, or that of its
Members or Representatives. Authors consent to the publication of this Technical Paper in the Rio Pipeline
Conference and Exhibition 2019.

Abstract

Flexible pipes are increasingly popular in the oil and gas industry for the development
of deep-water fields, for example offshore Brazil, and small fields in mature regions such as
the North Sea. Flexibles are complex structures, and the options for inspection to confirm
their integrity as they age are limited but developing. As inspection technology – internal and
external – advances in capability, the focus will transfer to the integrity assessment and
detailed analysis of the data through generation of models and methodologies. In parallel with
inspection technology development, we are also developing methodologies to utilize the data
collected and link the results with the risk assessments, integrity management strategy and
remaining life evaluation activities that all operators need to complete. The combination of
failure mode knowledge and inspection data will allow the industry to perform
complementary analysis for verification against the as-designed concept, enabling the
identification of potential life extension and enhancing risk management.

Keywords: In Line Inspection. Flexible Pipe.

1. Introduction

The global demand for flexible pipes continues to grow. With the adaptability of FPSO’s
taking offshore developments into deeper waters and allowing for the fast track short term
developments of small fields, flexible pipes provide the required versatility and performance to
facilitate such developments.

Maintaining and even extending the operational integrity of these assets presents a significant
challenge for both Operators and Regulatory Authorities. A particular challenge is to
understand and assess remaining service life to avoid failure and to, where possible, manage
the replacement strategy. The means of achieving this lies in an integration of inspection
technologies and integrity management elements.
With over 16,000 km of flexible pipe in operation around the world, and with 75% of these
exceeding 15 years of operation, then the importance of the deployment of inspection tools and
the comprehensive development of anomaly assessment methodologies to match PDAM
(Pipeline Defect Assessment Manual) for rigid pipelines is indispensable.
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ROSEN is working to support operators by developing a dedicated integrity approach for

flexible pipes (FIMS) that combines fundamental risk based asset management theory with
appropriate available inspection technologies and condition assessment methods and models
that can use the data collected by inspection.

2. IM Solutions

In any asset management process there is a symbiotic relationship between an integrity

management system (IMS) and asset inspections. The IMS drives the need for data and
inspection technologies are developed to deliver that data. This interdependence can be clearly
seen in the management of rigid pipelines. Detailed pipeline integrity management system
(PIMS) have been developed that require information on a range of parameters, such as internal
and external corrosion rates, which are facilitated by the deployment of sophisticated ILI tools.

In an earlier publication (“Flexible pipe integrity management: Searching for the Holy Grail”
1),we explored the integrity management issues of managing flexible pipes. Following on from
that exercise we have been working to understand the requirements for developing an ILI tool
that provides inspection data for flexible pipe steel layers in support of the Flexible Pipe
Integrity Management System (FIMS)

2.1. ILI Development

Over the years ROSEN has

inspected millions of kilometres of rigid
pipelines and accumulated an unrivalled
level of knowledge and experience in
interpreting the condition of these
pipelines.

During ILI runs through offshore rigid

pipes it was inevitable that the inspection
tool would on occasions also pass
through unbonded flexible pipes and
continue to collect data. We are is now
utilizing the data collected from these
transits through flexible pipes. By
combining our knowledge of interpreting
ILI data with our research capability in Figure 1: Flexible Pipe Typical Structure
developing inspection tools, we are
developing ILI tool technology for the inspection of flexible pipes.

The tool is being designed to target, identify and categorise those features within a flexible pipe
that can lead to the types of failure reported in the Sureflex JIP (Section 4.3 - Database Results:
Experience of Damage & Failure in the JIP report2). Some of the layers will be inspected by
direct measurement, whilst the condition of others will, on the short term at least, be inferred
1
Pipeline International, June 2016 - Flexible pipe integrity management: Searching for the Holy Grail, by Paul
Birkinshaw & Andrew Burton, MACAW Engineering (Rosen Group), UK
2
J000621-00-IM-GLN-001 - Flexible Pipe Integrity Management Guidance & Good Practice Rev 1 - September
2017
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from collected and historical data and supported by further analysis. A combination of different
technologies and data acquisition methods will provide a process for assessing the metallic
layers within the structure. Combining technologies for the inspection of the carcass layer,
pressure and tensile armour wires and the riser configuration will present a true representation
of the flexible pipe condition and provide a comprehensive data set for input into the FIMS
assessment.

In discussions with manufactures, installers, operators, inspectors and other consultants it has
become clear that there is, across the flexible pipe market, a variety of inspection tool
requirements. This feedback clearly indicates the potential range of integrity issues which cause
day-to-day problems for operators and for which there are limited or no cost effective solutions,
such as damage to the outer sheath within an I-Tube which does not allow for cost effective
external inspection.

Incorporating these challenges into the forefront of the tool development, and with an
understanding of the feasibility of a solution, we have developed a specific road map and
technology qualification process with the overall goal of a comprehensive ILI technology for
flexible pipes3.

3. 4. Where To From Here

The work undertaken to date and summarised in the following sections allows certain
aspects of the reported failure types (see table 1) to be assessed, leaving a clear development
direction for the remaining layers. We have started by evaluating the data being collected during
ILI runs through flexible pipes using existing technology to offer some small incremental
improvements in support of the long term integrity management and life evaluation of flexible
pipes. This process also allows us to demonstrate to stakeholders the potential benefits of
continuing to support these developments, which are by their nature time consuming, costly
and have to compete for attention with many other ILI technology developments.

Table 1: J000621-00-IM-GLN-001 – Damage / Failure Cause

We are working towards further development of existing technology and development of new
technology over the coming months and years to fill in the gaps. The objective being to have a
flexible inspection capability that will allow for common threats to the integrity of the flexible
pipe to ne effectively managed.
3
Flexible pipe integrity management: Moving towards the Holy Grail of ILI technology for flexible pipes, by Paul
Birkinshaw, Andrew Burton and Roland Palmer-Jones - Rosen UK.

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4. Carcass Inspection

In 2016 we undertook laboratory testing and

evaluation of existing ILI technologies to identify Figure 2: Flexible Pipe Carcass Profile
possible solutions for inspection of a flexible pipe
carcass layer4. ROSEN are constantly evaluating and
developing new sensors, and one such development is
an evolution of its DXD sensor into the DRD sensor.
The DRD sensor has been specifically designed for the
accurate measurement of the flexible pipe carcass but
it can also be used to inspect rigid pipelines. This
enables the first industry tool for the inspection of the
internal surface of an offshore pipeline system that
includes both rigid and flexible pipes.
The carcass used in a flexible pipe is made from
various grades of steel strip, formed into a defined
Figure 3: Flexible Pipe Test Sample
profile to resist collapse, which is
helically wrapped and interlocked,
Figure 2. The carcass materials are
susceptible to the fluid composition,
sand erosion and mechanical loading.

In late 2017 we performed tool

verification pull tests on a 15m long
sample of 9” diameter flexible pipe
Figure 3. This pipe was in an “as new” condition with no internal defects. The ILI tool was
winched through the pipe at different inspection speeds to characterize the tool performance
and evaluate sensor performance. Analysis of the collected data verified that the measurement
accuracy was sub-millimetre and so features within the carcass layer could be detected and
characterized to support FIMS, Figure 4.
4
IBP2058_17 - Technical challenges of inline inspection of offshore unbonded flexible pipes and enhancement
of integrity management practices, by Yijun Shen, Andrew Burton, Paul Birkinshaw, Roland Palmer-Jones.

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Figure 4: Flexible Pipe DRD Carcass Data

4.1 Pitch and Gap

The pitch and gap of the carcass layer was measured to identify any excessive sections of
carcass compression or extension. Given the flexible was in an “as new” condition, then the
inspection results were key in developing software to assess the pitch and gap. The data shows
a spread in the band of results of approximately 1.5mm with a standard variation of 0.4mm. We
are now in the process of targeting a standard variation of 0.1mm for the results, Figure 5.

Figure 5: Carcass Pitch and Gap Measurement

Signs of extension of the carcass could be a precursor indicator of a developing potential
problem i.e. tensile wire failure allowing for “stretching” of the flexible pipe.

Through the high level of detail obtained during the inspection of the carcass layer; erosion,
corrosion and cracking, along with localized deformation, can all be identified as shown in
Figure 6, which shows results for a small laboratory sample. This will support different
engineering assessments to compare against the original design considerations for collapse,
either through mechanical or hydrostatic loadings.

Figure 6: Carcass Cracks, Corrosion and Erosion

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5. Flexible Pipe Configuration

By assessing the data collected in 0.1m increments by the inertial measurement unit (IMU), we
can produce an as inspected flexible flowline and riser curvature configuration.

For the purpose of onshore pipelines, assessments are made to determine the strain levels
associated with bends and in conjunction with ground marker points the overall route and depth
of cover can also be determined, Figure 7. When considering the offshore environment the
focus of the IMU data is used to determine the bending strain level within the pipeline only as
reliable reference points for overall positioning are generally not available.

Figure 7: IMU Pipeline Route

The same process can be

applied to flexible flowlines and
risers, however the adaptation
of the process for flexible risers
involves measuring the changes
in curvature along the inspected
length only. The data allows for
a string model to be generated
which can then be imported into
the selected analysis software
which can then be pinned to
known reference points,
typically the subsea end fitting
for risers.

Figure 8: Typical Flexible Pipe Riser Configuration

Typical ILI tool speeds will
mean that in most scenarios the
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flexible riser will be mapped from seabed to topside, or vice versa, in a matter of minutes from
first end fitting entry. This allows for production of a very accurate riser configuration which
can be compared against the “as designed” and assessed configuration, Figure 8.

Each input parameter and variation of it (sensitivity analysis), at the design stage can have a
significant impact on the overall results. Inputs into the analysis program include such flexible
pipe parameters as ID, OD, weight, etc. along with the vessel and environment data. One of the
difficult challenges is modelling the pipes’ bending stiffness, which will typically fall into one
or more of the following approaches;
 Full slip bending model
 Stick to slip bending model
 Stick bending model
 Non-linear bending model

Figure 9: Strain Plots (Curvature vs Length)

One of the outputs from the analysis is a curvature vs length plot for the flexible pipe which
will have defined mean, maximum and minimum ranges for the analyzed load cases, Figure 9.

The curvature data collected by the IMU while the flexible pipe is operating would be expected
to fall within the range predicated by the analysis for the given operating conditions. Any
discrepancies identified between the predicted curvature and measured curvature can be used
to refine the base model thus enabling improved accuracy in the associated prediction of peak
stresses and fatigue life calculations. Discrepancies may be an indication of problems with the
flexile pipe such as loss of buoyancy units, touch down position movement etc. Given that
design analysis are typically conservative this approach is expected to allow life extension of
the flexible pipe and less restrictive station keeping for the vessel.

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6. The Final Stages

The final stages of the current development will present another significant step towards an ILI
tool that can provide a comprehensive inspection technology for flexible pipes. The remaining
metallic layers of significant interest, i.e. pressure and tensile armour, and will require ROSEN
to push the boundaries of its existing technology.

The significant challenge in inspection of these layers is the distance from the sensor to the
overlying layers. We have undertaken substantial laboratory testing of our existing technology
and are in the process of enhancing these technologies to address this issue for the overlying
metallic layer with initial results presented in Figure 10.
As with the carcass layer technology, the pitch and gap for identification of loss of interlock,

Figure 10: Pressure Armor Inspection

the detection of corrosion for reduction in cross sectional strength and the discovery of cracks
in the pressure armour layer will support the detailed integrity management process for these
carbon steel layers.

We have also assessed ILI data for the

detection of external ancillary
components. The detection of a mid-
water arch clamp and its location was
clearly aligned with the ILI odometer,
Figure 11. The location can be
evaluated against the “as installed” and
designed configuration and any
detected deviation can be evaluated in
conjunction with other data to assess
the overall integrity impact.

Figure 11: Mid Water Arch

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7. Summary
 In-line inspection has been widely adopted as a key source of data for the integrity
management of traditional rigid pipelines.

 The development of ILI technologies that can inspect all layers of flexible pipes would
provide the industry with a step change in the integrity management of this asset type.

 It is apparent that by combining knowledge in ILI technology (what can and cannot be
detected) and expertise in flexible pipes (what is the structure and what are the failure
mechanisms), valuable information can be obtained contributing to the effective
integrity management of flexibles. Specifically;
o Damage to the anti-collapse layer
o Gross dimensional changes
o Improved operational performance modelling

 Although a complete internal inspection solution to identify all possible damage in

flexibles is not yet available, internal inspection and other existing ILI technology can
reveal a lot of very useful information.

 In summary, with specialist experience in the design, analysis, manufacturing and

operation of offshore flexible pipes, combined with very strong technical capabilities in
pipeline in-line inspection, we are now developing assessment processes that will allow
operators to maximize the value of the data collected by the product development so far.

 The adoption of these partial solutions will help the industry to reduce uncertainty in the
conditions of flexible pipes providing an opportunity to learn more about what the
limitations of the existing technology are. This process will also generate the drive needed
to push development towards the goal of a comprehensive inspection system.

 We are also actively investigating new sensor technologies, which - when combined with
appropriate assessment methods - will provide more data to help in risk-based integrity
management of flexible pipe.

8. References

1. Pipeline International, June 2016 - Flexible pipe integrity management: Searching for
the Holy Grail, by Paul Birkinshaw & Andrew Burton, MACAW Engineering (Rosen
Group), UK
2. J000621-00-IM-GLN-001 - Flexible Pipe Integrity Management Guidance & Good
Practice Rev 1 - September 2017
3. Flexible pipe integrity management: Moving towards the Holy Grail of ILI technology
for flexible pipes, by Paul Birkinshaw, Andrew Burton and Roland Palmer-Jones -
Rosen UK.
4. IBP2058_17 - Technical challenges of inline inspection of offshore unbonded flexible
pipes and enhancement of integrity management practices, by Yijun Shen, Andrew
Burton, Paul Birkinshaw, Roland Palmer-Jones.